MODEL 808/847 UNIVERSAL PID … 808/847 UNIVERSAL PID PROGRAMMER/CONTROLLER MODEL 809/849...

MODEL 808/847 UNIVERSAL PID PROGRAMMER/CONTROLLERMODEL 809/849 THREE-STATE VALVE POSITIONERPROGRAMMER/CONTROLLER

Contents

Chapter 1 SAFETY, EMC AND GENERALINFORMATIONSafety..........................1-1 1Electromagnetic compatibility. . . . . . . . . . . . . 1-lGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . l - l

Unpacking and storage . . . . . . . . . . . . . . . . . l - l

General description . . . . . . . . . . . . . . . . . . . . 1 - 1SERVICE AND REPAIR. . . . . . . . . . . . . . . . . . . l - 2

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . l - 2

INSTALLATION SAFETY REQUIREMENTS. . . . . l - 3

Safety symbols. . . . . . . . . . . . . . . . . . . . . . . . 1-3Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . l - 3Enclosure of live parts . . . . . . . . . . . . . . . . . . l - 3

Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l - 3Power isolation . . . . . . . . . . . . . . . . . . . . . . . l - 3

Earth leakage current. . . . . . . . . . . . . . . . . . . l - 4

Overcurrent protection.. . . . . . . . . . . . . . . . . l - 4

Voltage rating . . . . . . . . . . . . . . . . . . . . . . . . l - 4Conductive pollution . . . . . . . . . . . . . . . . . . . l - 4

Over-temperature protection . . . . . . . . . . . . . l - 4

Grounding of the temperature sensor shield . . l-5INSTALLATION REQUIREMENTS FOR EMC . . . l - 5

Routing of wires. . . . . . . . . . . . . . . . . . . . . . . l - 5

Chapter 2 INSTALLATIONDimensions and panel mounting . . . . . . . . . . 2-lElectrical connections. . . . . . . . . . . . . . . . . . . 2-2Connecting terminals. . . . . . . . . . . . . . . . . . . 2-3

Mains supply and earth . . . . . . . . . . . . . . . . . 2-3Output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4

Output 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Output 3, Alarm . . . . . . . . . . . . . . . . . . . . . . 2-7Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Thermocouple input. . . . . . . . . . . . . . . . . . . . 2-7

808/847 & 809/849 Installation and Operating Instructions HA021 428 Iss 8 Cont.i

Chapter 3

Chapter 4

Chapter 5

Chapter 6

Chapter 7

Chapter 8

Resistance thermometer (RTD) Pt1 00,three-wire device. . . . . . . . . . . . . . . . . . . . . . 2-8Linear input (Option QLS . ...) . . . . . . . . . . . . . . 2-8Digital communications (option) . . . . . . . . . . . 2-9Programmer/controller (option QP...),setpoint programming option. . . . . . . . . . . . 2-1 1

TECHNICAL SPECIFICATION

PRODUCT CODE

OPERATIONOperating structure . . . . . . . . . . . . . . . . . . . . 5- 1Operating modes . . . . . . . . . . . . . . . . . . . . .5-2Control algorithms. . . . . . . . . . . . . . . . . . . . . 5-2Front panel identification . . . . . . . . . . . . . . . . 5-3Operating procedures . . . . . . . . . . . . . . . . . . 5-5Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7Sensor break. . . . . . . . . . . . . . . . . . . . . . . . .5-8Self-test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

CONFIGURATION LEVEL, OPERATOR LEVELConfiguration link/switch . . . . . . . . . . . . . . . .6-1Hardware configuration . . . . . . . . . . . . . . . . .6-2Parameter list . . . . . . . . . . . . . . . . . . . . . . . .6-3Pre-configuration, parameter setting . . . . . . .6-10Cutback . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

PARAMETER ACCESS AND CALIBRATIONParameter access protection. . . . . . . . . . . . . . 7-1Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

PROGRAMMER/CONTROLLERProgrammer/controller - Function. . . . . . . . . . 8-1Programmer/controller - States. . . . . . . . . . . . 8-2Programmer/controller - Holdback. . . . . . . . . 8-3Programmer/controller - -Setpoint programming

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4Programmer/controller - Annunciators . . . . . . 8-5Programmer/controller - Parametermodification . . . . . . . . . . . . . . . . . . . . . . . . . 8-5Ending a program. . . . . . . . . . . . . . . . . . . . . 8-6Program recovery following loss of power. . . . 8-7

Cont.ii 808/847 & 809/849 Installation and Operating Instructions

Chapter 9 SELF-TUNINGSelf-tuning - General. . . . . . . . . . . . . . . . . . . 9-lSelf-tuning - Activation. . . . . . . . . . . . . . . . . . 9-2Self-tuning - Operation . . . . . . . . . . . . . . . . . 9-2Self-tuning - Abort conditions. . . . . . . . . . . . . 9-7

Chapter 10 INSTRUMENT REGISTER

Chapter 11 SUPPLEMENTS- Relating to 808/809 valvepositioner controllersValve positioner controller (motor open/close) 1 1 - 1Additional parameters for valve positionercontroller . . , . . . . . . . . . . . . . . . . . . . . . . . 11-2Self-tuning for valve positioner controller . . . 11-2

808/847 & 809/849 installation and Operating Instructions Cont. iii

General

SAFETY, EMC AND GENERAL INFORMATION

Please read this section carefully before installing the controllerThis controller is intended for industrial temperature and process control applications when itwill meet the requirements of the European Directives on Safety and EMC. Use in otherapplications, or failure to observe the installation instructions of this handbook may impair thesafety or EMC protection provided by the controller. It is the responsibility of the installer toensure the safety and EMC of any particular installation.

SafetyThis controller complies with the European Low Voltage Directive 73/23/EEC, amended by93/68/EEC, by the application of the safety standard EN 61010.

Electromagnetic compatibilityThis controller conforms with the essential protection requirements of the EMC Directive89/336/EEC, amended by 93/68/EEC, by the application of a Technical Construction File.This instrument satisfies the general requirements of an industrial environment as described byEN 50081-2 and EN 50082-2. For more information on product compliance refer to theTechnical Construction File.

GENERALThe information contained in this manual is subject to change without notice. While everyeffort has been made to ensure the accuracy of the information, Eurotherm Controls shall notbe held liable for errors contained herein.

Unpacking and storageIf on receipt, the packaging or the instrument are damaged in any way, do not install orcommission the product. Contact your nearest Eurotherm Controls agent as soon as possible.If the instrument is to be stored before use, protect from humidity and dust in an ambienttemperature range of -30°C to +75 deg C.The packaging should contain an instrument mounted in its sleeve, two mounting brackets forpanel installation and this operating book. Certain ranges are supplied with an input adapter.

General descriptionModels 808 and 847 are digital temperature controllers. The 809 and 849 are valve position-ing controllers. The 808 and 809 are mounted upright, (vertical) and the 847 and 849 aremounted on their side (horizontal).Two LED displays indicate the operating parameters. The top display indicates the actualvalue, (PV) and the lower display indicates the setpoint, (SP). Other LED beacons indicatethe mode of operation, (see Chapter 5, Operation).Parameters and configuration values are set by use of the front panel keys. The PAR buttonselects the parameter and the up and down arrows are used to alter their value. In configura-tion mode each parameter can be defined as ‘read only ,’ ‘read / write’ or ‘hidden’. Thecontroller can be switched directly from automatic (closed loop) operation to manual bymeans of the A/M button.

808/847 & 809/849 Installation and Operating Instructions l - l

General

Without change of the hardware the main process variable input of the instrument can beconfigured to suit various thermocouples and resistance thermometers, (PtlOO). Recalibrationis not necessary for this procedure. Signals up to 25V can be accommodated by using inputadapters in the linear input option. Linearisation is scaleable within the display range of -999to 9999, with tenths display resolution.The controller is also equipped with a ramp to setpoint function. This enables it to automati-cally adjust the setpoint to give a defined rate of change of the process temperature. In theprogrammer version, two ramps and two dwell periods may be set.The modular construction of the instruments allows up to three output channels to performvarious functions. The instrument can be configured as a heat cool controller with one alarm,or a heat only controller with two alarms. The heat output may be fitted with a dc output.For communications with a host computer system the instrument can be fitted with either anEIA 232 or EIA 422 digital interface. This enables the automatic recording of measuredvalues on a printer, or the use of a proprietary supervisory system such as Eurotherm ControlsESP package.

SERVICE AND REPAIRThis controller has no user serviceable parts. Contact your nearest Eurotherm Controls agentfor repair.

Caution: Charged capacitorsBefore removing an instrument from its sleeve, disconnect the supply and wait at least twominutes to allow capacitors to discharge. Failure to observe this precaution will exposecapacitors that may be charged with hazardous voltages. In any case, avoid touching theexposed electronics of an instrument when withdrawing it from the sleeve.Electrostatic discharge precautionsWhen the controller is removed from its sleeve, some of the exposed electronic componentsare vulnerable to damage by electrostatic discharge from someone handling the controller. Toavoid this, before handling the unplugged controller discharge yourself to ground.

CleaningClean the instrument sleeve and the front facia with an anti-static cleaner and a soft cloth.Do not use water or water based products to clean labels or they will become illegible.Isopropyl alcohol may be used to clean labels.

1-2 808/847 & 809/849 Installation and Operating Instructions

General

lNSTALLATlON SAFETY REQUIREMENTS

Safety SymbolsVarious symbols are used on the instrument, they have the following meaning:

Caution, (refer to the I Functional earth. accompanying documents) (ground) terminal

The functional earth connection is not required for safety purposes but to ground RFI filters.

PersonnelInstallation must only be carried out by qualified personnel,

Enclosure of live partsTo prevent hands or metal tools touching parts that may be electrically live, the controllermust be installed in an enclosure. It is recommended that you use the rear terminal cover pro-vided.

Caution: Live sensorsThe fixed digital input and the non-isolated dc and logic outputs, are all electrically connectedto the main process variable input. If the temperature sensor is connected directly to an elec-trical heating element then these non-isolated inputs and outputs will also be live. The con-troller is designed to operate under these conditions. However you must ensure that this willnot damage other equipment connected to these inputs and outputs and that service personneldo not touch connections to these i/o while they are live. With a live sensor, all cables, con-nectors and switches for connecting the sensor and non-isolated inputs and outputs must bemains rated.

WiringIt is important to connect the controller in accordance with the wiring data given in this hand-book.

. Take particular care not to connect AC supplies to the low voltage sensor input or otherlow level inputs and outputs.

. Only use copper conductors for wiring connections, (except for thermocouple inputs).

. Ensure that the wiring of installations comply with all local wiring regulations. In theUK use the latest version of the IEE wiring regulations, (BS 767 1). In the USA useNEC Class 1 wiring methods.Unused terminals should not be used as ‘tie points’.

. Ensure the correct polarity of signal connections.

Power IsolationThe installation must include a power isolating switch or circuit breaker. This device shouldbe in close proximity to the controller, within easy reach of the operator and marked as thedisconnecting device for the instrument.

808/847 & 809/849 installation and Operating Instructions 1-3

General

Earth leakage currentDue to RFI Filtering there is an earth leakage current of less than 0.5mA This may affect thedesign of an installation of multiple controllers protected by Residual Current Device, (RCD)or Ground Fault Detector, (GFD) type circuit breakers.

Overcurrent protectionTo protect wiring and the PCB tracking within the controller against excess currents, the ACpower supply to the controller and power outputs must be wired through the fuse or circuitbreaker specified in the technical specification.

Voltage ratingThe maximum continuous voltage applied between any of the following terminals must notexceed 264Vac:

. line or neutral to any other connection;

. relay or triac output to logic, dc or sensor connections;

. any connection to ground.The controller should not be wired to a three phase supply with an unearthed star connection.Under fault conditions such a supply could rise above 264Vac with respect to ground and theproduct would not be safe.Voltage transients across the power supply connections, and between the power supply andground, must not exceed 2.5kV. Where occasional voltage transients over 2.5kV are expectedor measured, the power installation to both the instrument supply and load circuits shouldinclude a transient limiting device.These units will typically include gas discharge tubes and metal oxide varistors that limit andcontrol voltage transients on the supply line due to lightning strikes or inductive load switch-ing. Devices are available in a range of energy ratings and should be selected to suit condi-tions at the installation.

Conductive pollutionElectrically conductive pollution must be excluded from the cabinet in which the controller ismounted. For example, carbon dust is a form of electrically conductive pollution. To secure asuitable atmosphere in conditions of conductive pollution, fit an air filter to the air intake ofthe cabinet. Where condensation is likely, for example at low temperatures, include a thermo-statically controlled heater in the cabinet.

Over-temperature protectionWhen designing any control system it is essential to consider what will happen if any part ofthe system should fail. In temperature control applications the primary danger is that the heat-ing will remain constantly on. Apart from spoiling the product, this could damage any processmachinery being controlled, or even cause a fire.Reasons why the heating might remain constantly on include:

. the temperature sensor becoming detached from the process;thermocouple wiring becoming short circuit;

. the controller failing with its heating output constantly on;

l - 4 808/847 & 809/849 Installation and Operating Instructions

General

. an external valve or contactor sticking in the heating condition;

. the controller setpoint set too high.Where damage or injury is possible, we recommend fitting a separate over-temperature protec-tion unit, with an independent temperature sensor, which will isolate the heating circuit.Please note that the alarm relays within the controller will not give protection under all failureconditions.

Grounding of the temperature sensor shieldIn some installations it is common practice to replace the temperature sensor while the con-troller is still powered up. Under these conditions, as additional protection against electricshock, we recommend that the shield of the temperature sensor is grounded. Do not rely ongrounding through the framework of the machine.

INSTALLATION REQUIREMENTS FOR EMCTo ensure compliance with the European EMC directive certain installation precautions arenecessary as follows:

. For general guidance refer to Eurotherm Controls EMC Installation Guide,HA025464.

. When using relay or triac outputs it may be necessary to fit a filter suitable for suppressing the emissions. The filter requirements will depend on the type of load. Fortypical applications we recommend Schaffner FN321 or FN612.

s If the unit is used in table top equipment that is plugged into a standard power socket,then it is likely that compliance to the commercial and light industrial emissionsstandard is required. In this case to meet the conducted emissions requirement, asuitable mains filter should be installed. We recommend Schaffner types FN32 1 andFN612.

Routing of wiresTo minimise the pick-up of electrical noise, the wiring for low voltage dc and particularly thesensor input should be routed away from high-current power cables. Where it is impractical todo this, use shielded cables with the shield grounded at both ends. In general keep cablelengths to a minimum.

808/847 & 809/849 Installation and Operating Instructions l - 5

i ns ta l la t ion

INSTALLATION

Before installing this product read the safety and EMC information

Dimensions and panel mountingThe instrument is intended to be mounted into a front panel cut-out. Figure 2.1.1 shows thedimensions of the instrument and of the necessary front panel cut-out with tolerances. Behindthe instrument sufficient space should be provided for wiring.

+0.6045mm -o.oo

96mm

Front panel cut-outMaximum thickness 6mm

Figure 2.1.1 Dimensions and panel cut-out

Ventilation: The space behind the control panel must be sufficient to allow suitable ventila-tion to keep the ambient temperature within the permitted range.

To assemble, turn the screw on the front fascia in an anti-clockwise direction and pull theinstrument out of the sleeve. Now slide the plug-in sleeve into the control panel cut-out fromthe front. The two mounting brackets are fastened on the left and right hand side behind thecontrol panel and tightened with a screwdriver in a clockwise direction. A torque limiter pre-vents over-tightening.

For multiple installation in a control panel, the minimum spacings specified in Figure 2.1.2must be respected for adequate cooling.

In order to install the instrument to meet the NEMA3 rating (IEC IP54), an additional gasketkit is necessary. The kit consists of two self-adhesive neoprene gasket rings, these seal theinstrument to the instrument sleeve, and the sleeve to the front panel. The order number for thegasket kit is LA022339.

808/847 & 809/849 Installation and Operating Instructions 2-1

installation

at least50mm

at least50mm

Figure 2.1.2 Minimum spacings for multiple installation

Electrical connections

When wiring electrical equipment, please refer to the instructions in Chapter 1, Safety, EMCand General Information and Chapter 3 Technical Specification.

Before wiring, verify from the instrument label (on the side) which options have been builtinto the instrument and how the instrument is configured.

The terminals at the rear of the instrument are numbered from 1 to 20. Terminal allocation isshown in Figure 2.2.1.

WARNINGThe instrument has no in-built mains switch and is thereforepowered when the supply voltage is applied.

Note: Each output fitted with a relay or triac is equipped with an RC suppressor (snubber).Even when the output triac or relay is off, the snubber passes a current of 1mA whenconnected in a 120V AC circuit and likewise 2mA in a 240V AC circuit. When testing one ofthese outputs with a high input impedance voltmeter and the output is unloaded, the voltmeter


Installation

will read the line voltage even though the output is off. This does not indicate that the outputis faulty. Such a test should only be carried out when the output is loaded appropriately.

Logic o r D CD C o u t p u t 1 o n l y )

OV(-)

Signal (+)

ov (-)

Signal (+)

‘riac or Relay R S - 4 2 2 - A 11 1

1 2

1 3

1 4

1 5

1 6

1 7

1 8

1 9

20

C o m m o n I

4

5

6

7

Signal (+) OV (-)

R S - 2 3 2 - C

C o m m o n

TX

O v e r r i d e o f c o m m u n i c a t i o n sF r o n t p a n e l d i s a b l e

initiated

Logic R e l a y IT h e r m o c o u p l e / L i n e a ri n p u t ( w i t h i n p u t a d a p t e r )

Pt100

Figure 2.2.1 Terminal allocation

Connecting terminalsMains supply and earthThe controller can be powered by a mains voltage between 85 and 264 V AC / 50-60 Hz.Connect the Neutral to terminal 6 and the Live to terminal 5. A minimum of 0.5mm2 or 16awgwire is recommended. The earth ground of every single instrument should be directly connect-ed to the equipment copper ground bar. Do not connect several earth grounds of an instrumentas a chain (“daisy-chain” connection).

F u n c t i o n E x t e r n a l C o n n e c t i o n s T e r m i n a l s

L i ve

N e u t r a l

E a r t h

2 A

IS w i t c h m o d e

6 P o w e r S u p p l y

,

Figure 2.3.1 Mains supply, Terminals 5, 6 & 7


Installation

output 1Output 1 can be fitted with four output module types: triac (Tl), relay (Rl), logic (Ll) or DC(Dl). Check the relevant code on the instrument label. The external connections depend on thetype of output module installed. If output 1 is configured as time proportioned with powerfeedback, the mains supply of the instrument must be connected to the same Live as the load

supply.

output 2Output 2 can be fitted with four output module types: triac (Tl), relay (RI) or logic (Ll) orDC(D1). Check the relevant code on the instrument label. The external connections depend onthe type of output module installed.

Output 2 is configurable as either the cool channel or an alarm channel. If it is configured asan alarm channel, the output module cannot be a triac (Tl). In the alarm condition, the relay ofthis alarm output is energised, i.e. in the event of power-down or mains failure etc., the alarmrelay does not operate. For this reason this alarm should not be used for critical alarmapplications (not failsafe).

The following diagrams show terminal allocation for outputs 1 & 2.

WARNINGThe logic and dc outputs are not isolated from thethermocouple input.


Installation

F u n c t i o n

Triac (T1)Triac c o n d u c t s d u r i n g ONPhase ( y e l l o w OP1 l a m pON)

Relay (R1)

Relay c o n t a c t i s c l o s e dl u r i n g O N p h a s e ( y e l l o wOP1 l a m p O N )

Logic (L1)Logic output = +18VW i n g O N p h a s e o fOutput c y c l e ( y e l l o w OP1a m p O N )

DC (D1)

E x t e r n a l C o n n e c t i o n s T e r m i n a l s Internal Device

To mains 80 - 264V AC

50/60Hz

ov (-)

L o g i c s i g n a l ( + )+18V, m a x 1 10mA

DC signal (+)4-20mA / 0-20mA

Not Isolated from thermo

Figure 2.3.2 Output 1, Terminals 1 & 2


Installation

F u n c t i o n

Trriac (T1)Cool c h a n n e l o n l yi a c c o n d u c t s d u r i n g O hphase ( y e l l o w O P 2 l a m pON)

elay c h a n n e l

e l a y c o n t a c t i s c l o s e dduring O N p h a s e ( y e l l o w(OP2 l a m p O N )

l a r m O u t p u tContacts e n e r g i s e dduring a l a r m c o n d i t i o n(OP2 l a m p O N )

Logic Cool channel

Logic output = +1 O N p h a s e o f

output c y c l e ( y e l l o w O P 2w

output

o u t p u t = alarm condition O P 2 l a m p O N )

E x t e r n a l C o n n e c t i o n s T e r m i n a l s

T o m a i n s

,

ted

2AT o m a i n s I

80 264V ACI

L o g i c s i g n a l ( + ) max.

Not

DC signal (+)4 - 2 0 m A O - 2 0 m A

Internal Device

Figure 2.3.3 Output 2, Terminals 3 4

Installation and Operating instructions

Installation

Output 3, AlarmThis alarm channel can be fitted with relay (Rl) or logic (Ll) output module types. Check therelevant code on the instrument label. The external connections depend on the type of outputmodule installed.

When in the alarm condition, the alarm relay is de-energised. The alarm circuit connectedshould be fused and designed to operate in a failsafe manner, even in the event of a blownfuse.

In the alarm condition an appropriate annunciation appears on the LED display.

F u n c t i o n External Connections T e r m i n a l s I n te rna l Dev ice

R e l a y i s d e - e n e r g i s e dd u r i n g a l a r m c o n d i t i o n C l o s e d i n a l a r m

c o n d i t i o n

O p e n i n a l a r m . . . .

c o n d i t i o n9

I

I ICommon

10

Isolated from thermocouple inputI

Logic (Ll)Logic (l1) ILogic output = OVLogic output = OVd u r i n g a l a r m c o n d i t i o nd u r i n g a l a r m c o n d i t i o nO u t p u t s = +I 8V ( a c t i v e ,O u t p u t s = +1 8V ( a c t i v e ,

N o c o n n e c t i o n

high) during non alarmhigh) during non alarmc o n d i t i o nc o n d i t i o n L o g i c s i g n a l ( + )

.18V, max. 10mA

L o g i c

Figure 2.3.4 Output 3, Alarm, Terminals 8, 9 10

InputThermocouple and RTD inputs can be connected to the measured value input of the instru-ment, and linear input signals (millivolt and process signals with suitable input adapter) canalso be accommodated. For the possible types and ranges of input sensors, please refer to thesections on Technical Data (Section 3) and Product Code (Section 4).

Thermocouple inputConnections between thermocouple and controller must be made with the appropriatecompensating cable. Sensor break detection and an internal CJC (cold junction compensation)are built into the instrument. If the instrument is configured for external CJC, the connectionsbetween the CJC and the controller must be made with copper wire. Verify that correctpolarity is observed at the connection points.


installation

Resistance thermometer (RTD) Ptl 00, three-wire deviceConnect the single wire of the sensor to terminal 19 and the double wire to terminals 18 20.The length and gauge of all three wires must be equal. The cable resistance is compensated forby the three-wire device. Sensor break display is shown only if two wires break

Sensor E x t e r n a l C o n n e c t i o n s T e r m i n a l s

n o c o n n e c t i o n

Figure 2.3.5 Sensor input, Terminals 18, 19 20

Linear input (Option For input signals in the range to connection is made directly to the instrument.As a precaution against interference, a shielded, twisted pair should be used. The shield shouldonly be grounded at the sensor end.

For input signals greater than and process signals (per unit signals), a suitable inputadapter is available. This adapter is delivered with the instrument if ordered. Make sure that itis installed directly on to the instrument terminals. Again, use a shielded, twisted pair.

2-8 Installation and Operating Instructions

Installation

Process Signal(Option QLS only )

V o l t a g e A d a p t e r-10 . . . +50mV N O N E- 4 0 +200mV I A V 2-200 ... +1000mV IA1V-1 . . . +5V IA5V- 2 +10V 1A10V-5 . . +25V IA25V

C u r r e n t A d a p t e r-4 .. .+20mA I A A 0 2

E x t e r n a lConnections

I n p u t A d a p t e rT e r m i n a l s

A d a p t e rTYP IA...

ControllerT e r m i n a l s

Ground O

IV .

i n

t

Figure 2.3.6 Linear input, Terminals 18, 19 & 20

Digital communications (option)Verify on the instrument label if an EIA232 or an EIA422 interface is installed.

EIA232: Terminal 15 is for receiving (RX) and terminal 13 for transmitting (TX) on theEIA232 communications board, terminal 11 is common, This communications board isdesigned for point-to-point operation. Transmitting and receiving links are made between thesupervisory computer and the controller. The cable length should be limited to 15m.

EIA422: Terminal 11 is common and should be connected via a ground conductor to thesupervisory computer chassis, as a precaution against interference. The EIA422 communica-tions board uses terminals 14 (RX+) and 15 (RX-) for receiving and terminals 12 (TX+) and13 (TX-) for transmitting. This communications board is designed for a maximum of 32instruments. Cable lengths should be limited to a maximum of 1200m.

Front panel lock-out override: If terminals 16 & 17 are connected together for a shortperiod, lockout induced by a supervisory computer may be overridden. This function isnecessary if an error has been made in communication with the supervisory computer, andthere is a need to operate the controller manually despite the front panel lock-out. Furtherways of overriding a lock-out are by switching the instrument off for a short period or by anappropriate command from the supervisory computer.


Installation

If the instrument is configured as a programmer controller, terminals 16 17 no longerserve as a lock-out override, but instead take on functions associated with the programming option, see following sections.The digital communications output is isolated from the thermocouple input.

Figure 2.3.7 shows terminal allocation for in-built digital communications.

S t a n d a r d T e r m i n a l sE x t e r n a l C o n n e c t i o n s

f o r‘rant-panel

F r o n t p a n e / e n a b l e

S u p e r v i s o r

K e y s w i t c h f o rf r o n t - p a n e ll o c k o u to v e r r i d e

Figure 2.3.7 Digital communications, Terminals 11 to 17

2-10 Installation and Operating Instructions

Installation

Programmer controller (Option QLPS), programmingoptionIf the instrument is configured as a programmer controller (see instrument label), the RUNand HOLD states of a given program are controlled via terminals 16 17. Figure 2.3.8 showspossible connections. The function of the programmer controller is described in later sections

to start program (restart after HOLD/RESET)HOLD/RESET reset to beginning of program and hold

Model

Opt ion

A. S w i t c h

6. l o g i c w i t h o p t o - c o u p l e r

C . S e l f - l a t c h i n g r e l a y c i r c u i t

Figure 2.3.8 programming option, Terminals 16 17

WARNINGThe logic input are not isolated from the thermocoupleinput.

Installation and Operating Instructions 2-11

Technical Specification

TECHNICAL SPECIFICATION

Environmental ratingsPanel sealing:

Operating temperature:Relative humidity:Atmosphere:

Equipment ratingsSupply voltage:Supply frequency:Power consumption:Relay (isolated):

Triac outputs (isolated):Leakage current:

Over current protection:

Low level i/o:

Logic output (Non-isolated):DC output (Non-isolated):Fixed digital input:Digital Communications:

Address range:Baud rate:Character format:

GeneralDimensions:Weight:Resolution:Sample rate:Common mode rejection:Calibration accuracy:Cold junction compensation:

Maximum lead resistance:Thermocouples:Thermocouple linearisation:

Instruments are intended to be panel mounted. The rating of panelsealing is IP54, (EN 60529), or NEMA 3 when used with the optionalgasket kit, part number LA 022339.0 to 50°C. Ensure the enclosure provides adequate ventilation.5 to 95%, non condensing.The instrument is not suitable for use above 2000m or in explosive orcorrosive atmospheres.

85 to 264Vac.48 to 62Hz.5 Watts maximum.Maximum: 264Vac, 2A resistive. Minimum: lOVdc, 100mA.Channel 1 and 2 as form C, (closing contacts). Channel 3, (Alarm 1)as form A, (change-over contact).Maximum: 264Vac IA resis t ive . Minimum: 80Vac, 50mA.The leakage current through triac and relay contact suppressioncomponents is less than 2mA at 264Vac, 50Hz.External over current protection devices are required that match thewiring of the installation. A minimum of 0.5mm2 or 16awg wire isrecommended. Use independent fuses for the instrument supply andeach relay or triac output. Suitable fuses are 2A type T, (EN 60127time-lag type).All input and output connections other than triac and relay areintended for low level signals less than 42V.18V at 10mA (Max. current: 20mA).0 to 20mA (600W max.), 0 to 10V (500W min.).Contact closure, (non isolated).EIA-232, or 4-wire EIA-485, (both isolated). ANSI X3.28, subject 2.5and A4.00 to 99.Adjustable as: 300, 600, 1200, 2400,4800, 9600, 19200 Baud.7 data bits, even parity bit, 1 stop bit.

See Chapter 2.0.55Kg, (1.21bs) including sieeve and mounting clamps.12 bit, (0.7mV)125ms, corresponds to 8 measurements per second.>120dB at 264Vac, 50 / 60Hz.0.25% of reading, +l LSD or +l deg CInternal, >20: 1 rejection of ambient temperature.External configurable as 45°C or 50°C.1 OOORJ, B, E, N, K, L, R, S, PL2 and T.DIN 43710; DIN IEC 584 l(84); BS 4937 (73);ASTM E 230(72)


Technical Specification

Linearisation accuracy:RTD linearisation:Linearisation accuracy:Maximum lead resistance:

Electrical safetyStandards:

Installation category II:

Pollution degree 2:

Isolation:

Input/output functionsHeat:

Cool/alarm:

Alarm output:

Control parametersProportional band range:

Integral time:Derivative time:Hysteresis:

cutback:Relative cool gain multiplier:Output limit:Sensor break output:

limit:

Ramp-to-setpoint: 0.01 to 99.99 units per minute adjustable ramp-to-setpoint.

DIN 43760; BS 1904

EN 61010, Installation category II, pollution degree 2.CSA C22.2 Voltage transients on any mains power connected to the instrumentmust not exceed Conductive pollution must be excluded from the cabinet in which theinstrument is mounted.All isolated inputs and outputs have reinforced insulation to provideprotection against electric shock. The fixed digital input andnon-isolated logic and dc outputs, are all electrically connected to themain process variable input, (thermocouple).

(with or without ramp-to-setpoint function), DC or timeproportioned switching with adjustable cycle time (0.3 to powerfeedback configurable; ON/OFF with relay, logic and triac modules,hysteresis adjustable. Output action reverse or direct, configurable.Time proportioned switching with relay, logic or triac module,adjustable cycle time (0.3 to Cool characteristic (minimum ONtime): fan cooling linear oil cooling linear watercooling non-linear linear cooling (minimum ON time = 5% ofcycle time) configurable; output can also be configured as alarm (ifheat only).Two alarm outputs with full-scale high, full-scale low and deviationband alarm types configurable, each alarm type has its own setpoint,with 1 hysteresis. Alarm latching configurable for each alarm type.Alarm output 1 configurable as collective alarm for all alarm types,relay de-energised in alarm condition (failsafe); alarm output 2 config-urable, relay energised in alarm condition,

1 to (1 to 8100 “F) or 1 to 300% of the measurementrange; linear input 1 to 9999 units.1 to 8000 seconds or OFF.1 to 999 seconds or OFF.For ON/OFF controllers, as proportional band range in 1 to 1 to for start-up overshoot suppression.0.1 to 10.0 as a factor of the proportional band (heat).0.0 to 100% limit of control output.-99.9 to 0.0 to output, detects 10% of measurementrange over- or underrange.Upper and lower limit adjustable over the completemeasurement range.

3-2 installation and Operating Instructions

Product Code

Self-tuning:

Auto/manual behaviour:

Automatic adjustment of control parameters in start-up phaseor when required.Bumpless transfer to manual operation, adjustable -99.9 to 100.0%.

Programmer/controllerPrograms/segments:

Program parameters:

Holdback:

One program with four segments, consisting of ramp l/dwellperiod l / ramp 2/dwell per iod 2.0.01 to 99.9 units per minute setpoint ramp rate, target setpoint valuewithin measurement range, 0 to 9999 minutes dwell period, 1 to 200 orcontinuous program repeats.1 to 2000 (1 to 3600 “F), 1 to 9999 units linear / 0.1 to 500.0 (0.1 to 900.0 “F), 0.1 to 999.9 units linear with tenths’ precision;program hold in the case of control deviation.

Baud rate/character format: Adjustable 300,600, 1200,2400,4800,9600, 19200 baud, 7data bits, even parity bit, 1 stop bit.


Product Code

PRODUCT CODE

Basic instrument808, vertical instrument847, horizontal instrument809, vertical instrument849, horizontal instrumentOutput modules, Output 1 / 2 & alarmOutput 1, heatNo outputRelay, 2A /264 V ACLogic, 18 V I 20mATriac, /1A / 264 V ACDC, 0 to 20mA I 4 to /20mA max. 18 VOutput 2, cool or alarmNo outputRelay, 2A / 264 V ACLogic, 18 V / 20mATriac, 1A / 264 V AC, not for alarm configurationOutput 3, alarmNo outputRelay, 2A / 264 V ACLogic, 18 V / 20mACommunicationsNo communicationsRS 232RS 422Input adapter-10 to 50mV Ri = (standard, thermocouple)-40 to 2oOmv Ri = -0.2 to 1V Ri = -1 to 5V Ri = -2 to 10V Ri = -5 to 25V Ri = -4 to 20mA Ri = Special functionsPID controller with self-tuningProgrammer / controllerLinearisationFe/CuNi IEC 5841184 Type JFe/CuNi DIN 437 10 Type LNiCr/NiAl. Type KPtl3%Rh/Pt Type RPtlO%Rh/Pt Type SCu/CuNi Type TPlatinel IIPtlOO DIN 3-wire

Code808847809849

0RlLlTlDl

0RlLlTl

0RlLl

0c 2c 4

0IAV2IAlVIA5V

IA10VIA25VIAAO2

QLSQLPS

JLKRSTPz


Product Code

Linear, with appropriate input adapter, see calibration code XMeasurement range B N E J L K P R S T Z Code-250 to +250 . A-100 to +l00 . . . B-100 to +400 . . . . C-75.0 to +400.0 . . . . D0 to +100 . . . . . . . . . . E0 to +200 . . . . . . . . . . F0 to +300 ! ! ! ! # ! ! ! ! !

$

0 to + 4 0 0 . . . . . . . . . H0 to 1-600 ! ! ! ! ! ! ! #

0 to +800 . . . . . . K0 to +1000 . . . . . . L0 to +1200 . . . . . M0 to +1600 . . N200 to 800 # PLinear: Specify in the calibration code input range and input signal (mV, V, mA) and displayrange (max. -999 to 9999 or -99.9 to 999.9) with units (use only A to Z or a to z - these are forreference and do not appear on the LED display). XTenths’ precision configurable for J and L thermocouples.Measurement range for PtlOO (code Z), as a general rule with tenths’ precision.Units

C (measurement ranges on request) F

Linear, see calibration code XOutput configuration, outputs 1 / 2 and alarmOutput 1, HeatNo output 0Slow cycle time, for output modules Rl / Tl / Ll 1Fast cycle time, for output modules Tl / Ll 20 to 20mA, for output module Dl 34 to 20mA for output module D 1 4ON/OFF for output modules Rl / Tl / Ll , only if output 2 = alarm or no output,not for ramp-to-setpoint or setpoint programmer 5Output 2, cool or alarmNo output 0Water cooling 1Oil cooling 2Fan cooling 3Full-scale low alarm 4Full-scale high alarm 5Deviation band alarm 6Alarms non-latching (standard), relay energised in alarm condition. Alarm latching config-urable.


Product Code

Output 3, alarm CodeNo alarm 0Full-scale low alarm 4Full-scale high alarm 5Deviation band alarm 6Alarms non-latching (standard), relay de-energised in alarm condition. Alarm latchingconfigurable.Operating instructions, a manual is enclosed in the packagingGerman GDREnglish ENGFrench (only 808 / 847) FRADutch (only 808 / 847) NED

Basic Output Modules Input SpecialInstrument Output 1 Output 2 Output 3 Comms. Adapter Functions Standard 8081847 E

Measurement Output ConfigurationLinearisation Range Units output 1 Output 2 Output 3 Manual

Calibration code for linear input:

Min.Input signal Measurement range

Max. Units Min. Max. UnitsmV, V, m AtoZ


Operating structureThe operation of the instrument is structured on two access levels. Within these levels, threeoperating modes and four control algorithms with their parameters may be selected.

Operator level: The operator level is intended for normal, everyday operation of the controllerat the plant, The modifiable parameters on this level are fixed by the commissioning engineerin the ACCESS menu.

Configuration level: The configuration level is intended for commissioning the instrument.Each parameter on the configuration level can be either:

readable and alterable readable only, not alterable hidden.

The configuration level is accessible by setting the configuration link/switch (see Figure 5.1.1)

ACCESS LEVELS

Figure 5.1 .l Operating structure


Operation

Operating modesThe controller can function in three different operating modes. In automatic or closed loop,the output of the controller is determined by the control algorithm. In the base condition, theprocess value and the setpoint appear on the LED display. The setpoint is modified by theraise and lower buttons. Changeover to manual is through the A/M button (if not locked out,see section 5.4).

If the controller is switched to manual operating mode, the output level is operator-adjustableby means of the raise and lower buttons, control is then open-loop. In the base condition, theprocess value and the output level appear on the LED display. Illumination of the ‘M’ beaconindicates manual operating mode.

If sensor break is detected at the input of the instrument, an output level defined by theoperator, (parameter SnbP) is given on the output. The control loop is open here as well. Forheat control, the parameter SnbP can be adjusted in the range 0 to lOO%, and for heat/coolcontrol, in the range -99.9 to 100%.

A sensor break or input error occurs if the input circuit is open or the measured value on theinput over- or underranges the linearisation span of the instrument. If the input circuit is open,or the measured value is overrange, the annunciation SnbP is shown on the upper display. Ifthe measurement is underrange (e.g. reversed, incorrect thermocouple connection) theannunciation ur appears. In both cases, the flashing ‘M’ beacon indicates that the output levelis set at the value determined by the parameter SnbP.

Control algorithmsFour different control algorithms can be configured:

. ON/OFF controller (heat only, no cool)

. PID controller with immediate setpoint modificationPID controller with ramped setpoint modification

. PID programmer/controller with four segments (option QLPS)

Configured as an ON/OFF controller, the instrument functions as a two-state controller with acontrol switch point (heat output only).

The PID control algorithm includes self-tuning and special parameters for optimal start-up.For setpoint modifications, an adjustable ramp-to-setpoint can be entered which preventsexcessive thermal shock to sensitive loads.

Configured as a programmer/controller, the instrument moves through a temperature/timeprofile with four segments.


Oaeration

Front panel identificationThe instrument is operated and also configured by means of four pushbuttons and displays onthe front fascia (Figure 5.4.1).

Displays:The upper display indicates the measured value when in the base condition. On selecting aparameter, the appropriate parameter abbreviation appears. If one of the configured alarm con-ditions occurs, the display flashes.

The lower display indicates the setpoint when in the automatic mode and the output level setwhen in the manual mode. On selecting a parameter, the appropriate parameter value appearshere. If one of the alarm conditions occurs, the display alternately flashes alarm type and set-point.

Both the LED beacons ‘OP 1’ and ‘OP 2’, indicate the state of the relevant output. The LEDis illuminated when the output is ‘on’.

If output 1 is fitted with a DC output, the intensity of the beacon varies with the magnitude ofthe output level. If the DC output is configured as 4 to 20mA the LED glows dimly even withan output level of 0%.

If output 2 is configured as an alarm output, the LED is illuminated when the alarm is active.

The LED beacon in the upper left comer of the display flashes when the controller is in activecommunication with a host computer via the digital communications board (only if option‘digital communications board’ has been installed).

The LED beacon R in the upper display is illuminated when the setpoint is ramping towardsthe target setpoint (only if ramp-to-setpoint has been configured).

The LED beacon M indicates manual operating mode, the beacon flashes if sensor break isdetected.

Operating buttons:The defined parameter list is scrolled through in sequence using the parameter pushbutton(‘PAR’). By pressing the button, the abbreviation of the next parameter is shown in the upperdisplay. The value associated with this parameter is shown in the lower display. If no changeis made in the following six seconds by pressing the PAR button, the display returns to thebase condition. This time-out can be overridden by holding down the PAR button.

In alarm condition, a latched alarm is acknowledged by one press of the PAR button.


Operation

A. Communications in progressB Ramp-to-setpoint in progressC. Manual operating modeD Upper LED displayE Lower LED displayF Output 1 energised beaconG. Output 2 energised beaconH. Parameter/Scroll alarm acknowledge pushbuttonsI. Raise parameter value pushbuttonJ . lower parameter value pushbuttonK. Auto/manual operation selection pushbuttonL. Jacking screw

Figure 5.4.1 Front panel displays/buttons

With the lower pushbutton, the value of the displayed parameter is decreased (insofar asmodification is permitted). The speed increases as long as the button is depressed.

With the raise pushbutton, the value of the displayed parameter is increased (insofar as mod-ification is permitted). The speed increases as long as the button is depressed.

With the automatic / manual button (‘A/M’), the controller is switched from automatic

5 - 4 808/847 & 809/849 Installation and Operating Instructions

Operation

operating mode to the manual mode. Depressing the button again returns the controller toautomatic. The changeover is bumpless, the output level at the time of the changeover istransferred into the required operating mode. If the instrument is configured as an ON/OFFcontroller, the output level can only assume one of two values (0 or 100%). This button can belocked out in the configuration level, so that the instrument remains in the operating modechosen before lockout. If the instrument cannot be operated using the pushbuttons, either all ofthe parameters have been hidden or the front panel buttons are locked out through digital com-munications,

Operating proceduresAccording to its configuration, the instrument reacts in various ways to modifications to thesetpoint, parameters and operating procedures,

The reactions depend on the control algorithm configured:. PID controller with immediate setpoint modification. PID controller with ramped setpoint modification. PID programmer/controller with four segments (option QLPS)

PID controller with immediate setpoint modification:The setpoint can be freely modified between the configured limits (see parameter list), whenthe actual value is indicated in the upper display and the setpoint in the lower display. Thesetpoint modification is transferred by the controller immediately into the control algorithm.

Ramped setpoint modification:This function is configured in the parameter ‘Ctrl’ by selecting ‘r SP’ . Excessive thermalshock to sensitive loads is prevented by bumpless start-up to the required setpoint. Theramp-to-setpoint is independently activated by powering up the instrument or by modifyingthe setpoint. The instantaneous control setpoint is modified by adjustable ramping. It beginswith the original process value and ends with the adjusted target setpoint. The ramp rate isselectable by the ‘Sprr’ parameter in or alternatively display units/min.

During ramp-to-setpoint the process value is indicated in the upper display and the targetsetpoint in the lower. The R beacon is illuminated until the target setpoint has been reached. Inorder to view the instantaneous setpoint, the PAR button must be pressed once. The R beaconflashes during display of the instantaneous setpoint.

With the ‘Hb’ (holdback) parameter the maximum allowable deviation between the processvalue and the instantaneous setpoint can be defined. The value is directly entered in LEDdisplay units. If the deviation exceeds Hb, ramping is halted and the R beacon flashes. Thefunction of holdback is further explained below.

If the ramp rate or the target setpoint is modified during ramp-to-setpoint, this modificationdirectly affects active ramping, see Figure 5.5.1 for further clarification,


Operation

Original setpoinr Modified setpoint trajectorySetpoint trajectory

Target setpoint

target setpointe

B. Change in target setpoint: ramping leads to new target setpoint

Original setpoint target Original setpoint trajectory

Setpoint

Modified target

Change in Timetarget setpoint target setpoint

C . Change in target setpoint new setpoint already exceded by ramp

Figure 5.5.1 Parameter changes during ramp-to-setpoint


Operation

AlarmsTwo alarm outputs may be installed in the controller. Three different types of alarm can be setup with these alarm outputs by configuration:. Full-scale high alarm (H AO). Full-scale low alarm (L AO). Deviation band alarm (d AO)In the alarm condition, the alarm outputs fitted and configured with the appropriate modulesare energised. Alarm output 1 and alarm output 2 possess different characteristics.

Alarm 1 and Alarm 2lower display flashes

and/or

alternating with the setpoint

if

one of the alarm conditions,d e f i n e d b y t h e f o l l o w i n g

parameters, is active

H I

and/or A R

A. A/arm annunciation “Soft-a/arm”

Alarm 1upper display flashes

if

2AlarmLED ‘OP2’ is lit

MB

i s for

B. A/arm annunciation, a/arm outputs 1 and 2

Figure 5.6.1 Alarm annunciations


Operation

Alarm output 1 (fitted with the appropriate module) operates as the collective alarm for allconfigured alarm types, i.e. it operates if at least one of the configured alarm conditionsoccurs. The function of the alarm output can be configured for each type of alarm as ‘latching’(LAt), ‘non-latching’ (nLAt) or as ‘not active’ (OFF). If the appropriate alarm type is config-ured as non-latching, it is then a ‘soft-alarm’ in the instrument. In the alarm condition, thesetpoint on the lower display flashes alternately with the alarm type. If the alarm type isassociated with alarm output 1 by configuration of LAt or nLAt, a flashing of the actual valuein the upper display signals, additionally, the active alarm output.

One of the three possible alarm types can be associated with alarm output 2. The alarm out-put must be fitted with the appropriate module and should not be configured as a cool output.In an alarm condition the LED ‘OP 2’ signals the active alarm output.

If an alarm type is configured as ‘latching’, the alarm annunciation on the LED display mustbe acknowledged by pressing the ‘PAR’ button. Acknowledgement is not possible until afterthe alarm condition has cleared. With a non-latching alarm, the alarm annunciation disappearsas soon as the alarm condition has cleared.

Sensor breakIf a sensor break is detected at the input of the instrument, one of the output levels defined bythe user (SnbP parameter) is given on the output. The control loop is therefore open. TheSnbP parameter can be adjusted for heat control in the range 0 to 100% and for heat/cool con-trol in the range -99.9 to 100%.

A sensor break and likewise an input error occurs when the input is open circuit or the mea-sured value at the input over- or underranges the linearisation span of the instrument. If theinput is open circuit or the measured value is overrange, the annunciation SnbP appears on theupper display. In an underrange condition (reversed polarity or wrong thermocouple connec-tion) the annunciation ur appears. In both cases, the flashing M beacon indicates that the out-put level is set at the value defined by the parameter SnbP.

If, on the configuration level, a change in operating mode has been authorised to manual, theoperator can directly modify the output level with the raise or lower buttons. By pressing theA/M button once, the operator can enter definitively manual mode. This operating mode canonly be quitted after the sensor break condition has been corrected and by pressing the A/Mbutton again. If the manual operating mode is not abandoned, the output level cannot be mod-ified by the operator if a sensor break has occurred.

Self-testAn in-built self diagnostic routine checks the instrument for faults. If an internal instrumentfault occurs, the annunciation CErr is shown on the lower display. Close the configurationlink/switch and select, with the PAR button, the parameters CAch and EEch (at the end of theparameter list). Note the parameter values displayed and the version number of the softwareand return the instrument with details of the parameter values and a description of the fault, to

5-a 808/847 & 809/849 Installation and Operating Instructions

Operation

the nearest EUROTHERM branch for inspection. Under no circumstances should the faultyinstrument be used.

808/847 & 809/849 Installation and Operafing Instructions 5-9

CONFIGURATION LEVEL, OPERATOR LEVEL

Configuration

Configuration link/switchThere are over 30 parameters maintained in the non-volatile memory of the instrument. Theseparameters are pre-set according to the product code and corresponding standard values, butcan, however, be modified at any time by commissioning staff allowing for the available andexternally connected hardware.

The parameter list is presented differently in the operator level and the configuration level: inthe configuration level all the available parameters in the instrument are listed. In addition, amenu is available for calibrating and defining the modifiable parameters in the operator level.

In the operator level, only those parameters are listed which have been configured by the com-missioning staff in the ACCESS menu as ‘readable and alterable’ or ‘readable only, not alter-able’.

Thus, commissioning on the configuration level consists of the configuration and parameteri-sation of the instrument and determining which parameters should be shown and modified atthe operator level.

During the changeover to configuration level, the instrument must be removed from thesleeve, and the configuration link/switch (Figure 6.1.1) must be closed. After this the instru-ment is replaced in the sieeve and is powered up.

WARNINGConfiguration should only be undertaken by trained personnel

who are fully conversant with the instrument. For normalinstrument operation, the configuration link/switch shouldalways be open.

808/847 & 809/849 Installation and Operating Instructions 6-l

Configuration

R M

OP1 OP2

ConfigurationLink open =

operator level

Link closed =configuration level

F igu re 6 .1 .1 Con f igu ra t i on l i nk /sw i t ch

Hardware configurationIt is important to note in the configuration of the instrument that the configuration parameterspossible for an output (OP 1, OP 2 or AL 1) depend on the output module installed.Depending on the output module, only certain configuration values may be selected. Figure612.1 shows the possible combinations of configuration parameters with output module. Usethis table if re-configuring the instrument.

# = Permissible combination of configuration parameter and output module

Figure 6.2.1 :.Hardware configuration

6-2 808/847 & 809/849 installation and Operating Instructions

Configuration

Parameter listAll parameters available in the instrument are listed on the following pages. The sequence ofparameters corresponds to the sequence in the instrument, as it appears after pressing the PARbutton. Some parameters influence the appearance, and similarly the disappearance (HidE), ofother parameters, e.g. the cool cycle time is hidden if no cool output channel is configured.Other parameters depend on the firmware options of the instrument.

The first column in the parameter list contains the parameter abbreviation (mnemonic), as itappears when selected in the upper display. For those parameters which are continuously mod-ifiable, the adjustable range is listed; for those parameters having discrete values, the possibleparameter values are specified.

* indicates software version 02.00 and ** indicates software version 03.00

If the instrument is to be re-configured it is advisable first to fix the parameters Sn, CtrI, OP 1and OP 2, as many other parameters depend on these.

808/847 & 809/849 lnstallation and 0perating Instructions 6-3

Mnemonic Parameter Adjustable range Factory setting Comments

LOWER SP

None

C or F(plus activeprogramsegment)

LEVELSetpoint Upper limit: ‘SP H’

Lower limit: ‘SP L’25°C (70 “F)

Output level -99.9 to + 100.0% (heat/cool)0.0 to 100.0% (heat only)

Display units Display only

Displayed in auto without mnemonic.Displayed in manual with mnemonic.Becomes current program setpoint if ‘Ctrl’configured as ‘Prog’ and programmerstatus = ‘Run’, ‘Hold’, or ‘Hb’.Display only in manual, withoutmnemonic(‘M’ beacon is lit).No units for linear input. Active programsegment only if status is ‘Run’, ‘Hold’, or‘Hb’.

PROGRAMMER/CONTROlLER (Option QLPS...)Prog Programmer/controller Closed loop control

status (disploy & selection) Program running

SPProgram halted

Setpoint in closed loop Upper limit: ‘SP H’Lower limit: ‘SP L

tunE Active self-tune

IdlErunHold

OFF

These parameters appear only if ‘Ctrl’ is configured as ‘Prog idle

25°C (70°F)

O F F

LCrl

dlr2L2d2

onProgram repeat counter t oRamp rate 1

200 or (continuous)* 10.01 to 99.99 units/minute 1

Target setpoint 1Dwell time 1

Measurement range0 to

25°C (70°F)9999 minutes 1 minute

Ramp rate 2 0.01 to 99.99 units/minute 1Target setpoint 2Dwell time 2

Measurement range

0 to25°C (70°F)

9999 minutes 1 minute

PROGRAMMER/CONTROLLER (Option QLPS...)continued These parameters appear only f ‘Ctrl’ is configured as ‘Prog’Hb* Holdback 1 to 100” or units

(without tenth’s precision)Only appears if ‘Ctrl’ is configured as

1 to 3600°F ‘Prog’ or

1 to 9999 unitsHoldback 0.1 to 100.0” or units Tenths’ precision if measured range is so(with tenths’ precision) 0.1 to configured

0.1 to 999.9 units

ALARMii Hi Al Full-scale high alarm Measurement range M-range upper limit

Lo Al Full-scale low alarm Measurement range M-range lower limitd Al Deviation alarm 1 to 30°C (50°F),

(without tenths’precision) 1 to 3600°F

1 to 999.9 units

Devistion alarm 0.1 to Tenths’ precision if measurement range is(with tenths’ precision) 0.1 to so configured

0.1 to 999.9 units

CONTROL PARAMETERSProp Proportional band 1 to 4500°C (1 to 300%) 40°C (60°F) for ‘Pid’ Becomes hysteresis if control is

(without tenths’ precision; 1 to 8100°F (1 to 300%) ‘r SP” & ‘Prog’ configured as ‘On.of1 to 9999 units (1 to 810%) 3 (5°F) hysteresis

for ‘On.OfProportional band 0.1 to (1 to 450.0%) Unit corresponding to parameter Pb.d.(with tenths’ precision) 0.1 to (1 to 810.0%) Decimal point in lower right display

0.1 to 999.9 units (1 to 810.0%) indicates degrees or process units, nodecimal point indicates percentage.

Integral time constant OFF and 1 to 8000s 360sdEr.t

Disappears if ‘Ctrl’ = ‘On.OfDerivative time constant OFF and 1 to 999s 60s Disappears if ‘Ctrl’ = ‘On.Of

rEL.C Relative cool gain 0.1 to 10.0 0.5 (Water cooling) Disappears if ‘OP 2’ configured

H c.t Heat cycle time 0.3 to 80.0s

1 .O (Oil cooling)

2.0 (Fan cooling)20.0s (slow cycle)0.3s (fast cycle)

as alarm or ‘OFF’, or 'Ctrl = ‘On.Of’.

Parameter is output module dependent.Disappears if ‘OP 1’ configured as‘O-20’ or ‘4-20’ or ‘Ctrl’ = ‘On.Of’.

Parameter is output module dependent.


CONTROLc c.t

H cb

cb

(continued)Cool cycle time 0.3 to 80.0s 20.0s

High cutback 1 to 2000 start-up optimisation 1 to 3600 (without tenths’ precision) 1 to 9999 units

High cutback 0.1 to 500.0 start-up optimisation 0.1 to 900.0 with tenths’ precision 0.1 to 999.9 units

Low cutback As ‘H cb

Disappears if ‘OP 2’ configured as alarmor ‘OFF’, or ‘Ctrl’ = ‘On.Of’. Parameter

is output module dependent.

Appears only if ‘Cb 0’ parameter config.

as ‘HAnd’

As ‘H cb’

SETPOINT LIMITSSP HSP I.

Setpoint high limit

Setpoint tow limit

Measurement range

M e a s u r e m e n t r a n g ealways ‘SP L

always ‘SP H’

ALARM 1 OUTPUTHA0 Full-scale high alarm

LAO Full-scale low alarm

dA0 Deviation band alarm

LatchedNon-latched

Off (soft alarm)Latched

Non-latched

Off (soft alarm)LatchedNon-latched

Off (soft alarm)

LAtnLAtOFFLAtnLAtOFFLAtnLAtOFF

Parameter is output module-dependent



OUTPUT POWER/LIMITSH PL Max output powerSnbP Sensor break power

0.0 to 100%

-99.9 to + 100.0% (heat/cool)0.0 to 100.0% (heat only)

100%

0.0%

MEASURED VALUE INPUTOFst Input/calibration offsetCF unit selection

Sn Linearisation

-9.99 to 99.99D e g r e e s C e n t i g r a d e CDegrees Fahrenheit F thermocouple J tcK thermocouplePL2 thermocoupleR thermocouple r tcS thermocouple s tcT thermocouple t tcJ th’couple O’s prec) .JtcPtl 00, 3-wire rtd3L thermocouple tc **L th’couple O’s prec) **Linear input Lin *Linear input (l/l O’s prec) .Lin

These parameters appear only ‘Sn’ is configured0.00 or

Affects all temperature dependentparameters

DIGITAL COMMUNICATIONS BOARD Parameters appear even if no digital comms board installed, but are inoperativeAddr Instrument address 0.0 to 9.9 0 .0bAud Baud rate 300 baud 3 0 0

600 baud 6 0 01200 baud 1 2 0 04800 baud 4 8 0 09600 baud 9 6 0 019,200 baud 19.2

GENERAL CONFIGURATIONidno Identification number

Ctrl Control algorithm

SPrr Ramp-to-setpoint

0 to 9999 0 For communications board identificationNo direct control function

ON/OFF On-Of PIDPID PidPID with rbmp. to SP rSPPID program’r/controller Prog Available only if option QLPS... installed0.01 -to 99.99 units/min 10.00 Only appears if ‘Ctrl’ = ‘r SP

GENERALOP 1

OP2

AH

Pb d

(contioutput 1(hardware configuration)

output 2(hardware configuration)Cooling algorithm

Output 2 alarm

Digital output

Auto/manual enable

CJC reference selection

‘roportional band display

band scaleactorwithout tenths’ precision)

O-20mA O-204-20mA 4-20Time-proportioned with PFb

wed)Time-proportioned

power feedbackOf f OFFFan cooling, linear FAnOil cooling, linear O I LWater non-linear H20Linear, 5% cycle 0 . 0 5Latched high alarm HiNon-latched high alarm n HiLatched low alarm I. LoNon-latched low alarm n LoLatched deviation alarm dANon-latched dev. alarm n dAO n on *

Changeover locked out AutoChangeover possible HAnd

In ternal reference lnt0 external reference O C45 external reference 4 5 C50 external reference 5 0 C

or C-FLinear input units LinPercentage

1500°C18 to 2700 to 9999 units


Changeoverlocked out

Internal reference

/

Measurementrange as productcode

Parameter is output module dependent

Feedback of mains fluctuations: connectcontroller & load to same LiveParameter is output module dependentMin. 500ms unit‘Min. 35ms unitCondensing water cooling (35ms unit)Min. 5% of C c.t as unitOutput 2 alarm is not fail-safe,and therefore should not be used forcritical installations

Modifiable through digitalcommunicationsAfter lock-out instrument remoins inexisting operating mode automatic ormanual

Parameter appears only if ‘Pb d’ isconfigured OS Scale factor rangeis dependent on choice oflinearisation and units

Proportional band scale to 999.9 I I Set to measurment ranae90.0 to 999.9 0.1 to 999.9 unitsEnabled YES EnobledDisabled no

Cb * Cutback function Automatic value (3x Pb) AutomaticAdjustable parameter HAnd

LINEAR INPUT (Option QLS)Act Control action Automatic vReverse rEv Reverse (PV below

Direct dir SP heat)Hi Measurement ranae

upper limit break)-999 to 9999-99.9 to 999.9 (tenths’ precision)

L o I . Measurement range lower -999 to 9 9 9 9

FilProc

limit (sensor break) -99.9 to 999.9 (tenths’ precision)Input filter 0.01 to 99.99 or unitsProcess scaling (straight 1. Scaling pointline equation] 2. Scaling point P 2

1 unitInput signals for scaling should be asclose as possible to min & max ofmeasurement range

ACCESS LEVEL /ACCS Parameter access in Hidden HidE

operator level Read only rEAdReadable/alterable Altr

CAL Calibration procedure Sub menu header ----20mV reference 20.050mV reference 50.0CJC reference C J C

Ptl 00 reference rtdRetrieve original factory FACcalibration

These parameters appear only if ‘Sn is configured For security reasons, all critical parame

ters disoppear in the operator level (seespecific chapter)Calibration should only be undertakenby qualified personnel. The use ofprecision sources is essential(see specific chapter)

Does not calibratelinear input

Configuration

Pre-configuration, parameter settingA large number of parameters are installation-dependent, and as such only need setting oncebefore commissioning. This setting should take place before connecting the instrument to theplant, e.g. at a bench. In addition, these parameters should, for security reasons, be removedfrom the operator’s ACCESS menu (HidE).

WARNINGNever configure the instrument while it is controlling a process.

In the following paragraphs, some advice is given for parameter setting:Proportional band: With the Pb d parameter, one can select whether the proportional bandshould be displayed in units or in percentage. If the percentage setting is chosen, the range isdetermined using the PH-L parameter, to which the percentage data refers. The value shouldbe equal to the measurement range of the instrument.

ON/OFF controller: If the instrument is configured as an ON/OFF controller, the outputhysteresis is set using the proportional band (ProP). All other control parameters are hiddenfrom the parameter list.

Relative cool gain: This parameter (rEL.C) indicates the relationship between the heatingand cooling performance of the controlled equipment. By this means, a special proportionalband is defined for the cool channel, which is calculated from the value for the heat channeland the factor set in rEL.C. The parameter is set according to the ratio:

rEL.C = heat performance : cool performance

Therefore the heating/cooling effectiveness values of the controlled equipment must be knownor deduced. The parameter must be correctly set without fail before activating self-tuning, astuning relies on this value for calculating the control parameters.

Cycle time: The cycle time of the switching outputs (H c.t and C c.t) should be set to highvalues (e.g. 20 seconds) if contactors are used, and to low values (e.g. 1 second for logic out-put) if thyristors are used.

CutbackH cb and L cb are additional control parameters, which were developed by EUROTHERMspecifically for optimum start-up. Through their use, over- and undershoot can be avoided.(This is a normal occurrence in standard controllers when there is an excessive controldeviation leading to integral saturation). At the same time rapid settling is guaranteed, as thecontroller provides full output until the cutback point is reached. Cutback works by movingthe proportional band (H cb and L cb) to a determinedpoint during an excessive controldeviation.


Configuration

To adjust cutback, both parameters are set in the first instance to match the proportional band.Thus cutback is cancelled (switched off). The data is always in display units and musttherefore be recalculated in percentage for proportional band:for Pb in units: Hcb=Lcb=Pbfor Pb in %: H cb = L cb = Pb(%) x measurement range/100

Now the process is started up with a large control deviation and the degree of over- andundershoot is registered.

Low cutback can be adjusted by a start-up attempt with an actual value smaller than thesetpoint.

Low cutback: start-up attempt, actual value < setpoint

Process value Process valueA

-SetpointUndershoot- - - - - - - - - -

Time Time

The cutback value is shifted from its previous setting equal to the proportional band by theamount of the over- or undershoot. Taking the proportional band value into account in calcu-lating the low cutback, the setting rule is:for Pb in units: L cb = Pb + overshoot

L cb = Pb - undershootforPbin%: L cb = Pb(%) x measurement range/l 00 + overshoot

L cb = Pb(%) x measurement range/100 - undershoot.

The appropriate values for high cutback can be adjusted by a start-up attempt with an actualvalue greater than the setpoint (cooling).

High cutback: start-up attempt, actual value > setpoint

The setting rules for this are:for Pb in units: H cb = Pb + overshoot

H cb = Pb - undershootforPbin %: H cb = Pb(%) x measurement range/l00 + overshoot

H cb = Pb(%) x measurement range/100 - undershoot.

With the parameter Cb 0, a fixed value can be set for both cutback points. The cutback pointsare then set to 3 times the proportional band value and both parameters are hidden.

808/847 & 809/849 Installation and Operating Instructions 6-l 1

Calibration

Parameter access protectionThis menu defines the parameters which are modifiable at the operator level. The menu is onlyavailable when the configuration link/switch is closed. Here, each parameter is defined as towhether at the operator level it is:. ‘readable and alterable’ (Altr)

‘readable only, not alterable’ (rEAd). ‘hidden’ (HidE).

With the configuration link/switch closed, scroll down to the mnemonic ACCS using the PARbutton.By pressing the ‘raise’ button, the first parameter (HiAI) is called up. By using the ‘lower’button access can be set. Pressing the raise button again acknowledges the setting and movesthe selection on to the next parameter. Repeat this procedure until you have defined access foreach parameter.

By operating the PAR button, you can leave the access menu at any time. If no buttons arepressed within five seconds, the menu times out automatically.

808/847 & 809/849 Installation and Operating Instructions 7- l

Calibration

B U T T O N O P E R A T I O N :

1. Instrument configuration switch in‘CONFIG’ position.

2. Depress PAR button until displayshows:

3. Depress ‘raise’ button, first parameteappea rs :

4. Depress ‘lower’ button until desireda c c e s s a p p e a r s

5. Depress ‘raise’ button to advance ton e x t p a r a m e t e r

Assign access for all parameters

D I S P L A Y :

rA

Figure 7.1 .1 Parameter access protection

CalibrationBy virtue, of the drift-free design of the input circuit, it is normally not necessary to recalibratethe instrument after leaving the factory. Should an identifiable measurement error be detected,please note the following points:

On changing a thermocouple, the measured value can deviate (from the reading of the oldone). This deviation can be compensated by changing the parameter OFSt Temperature dif-ferences between the sensor location and the point of desired temperature measurement arecompensated by this as well. Differences between two side-by-side instruments are mainlydue to the above-mentioned reasons and do not require recalibration.

If recalibration is really necessary, there are two ways of proceeding: default to the originalfactory calibration or field calibration of the instrument.


Calibration

Factory calibration is stored in the non-volatile memory of the instrument, and can beretrieved at any time without the aid of calibration sources. For factory calibration, follow theinstructions given in Figure 7.2.1, the instrument must be set to configuration mode by closingthe configuration link/switch. Factory calibration must not be attempted while the instrumentis controlling a process.

Field calibration of the instrument should only be performed by trained and qualified person-nel. A precision calibration source is necessary for recalibration; it should be at least twice theaccuracy of the instrument itself (precision of calibration source 0.1%). The calibration sourcemust be equipped with an in-built CJC for type J thermocouples. In addition, appropriate typeJ compensating cable is required. For recalibrating the resistance thermometer input (RTD), aprecision decade resistance box (5 decades, 0 . 1 W steps, 0.02% precision) and copper wiremust be used.

B U T T O N O P E R A T I O N :

1 . Instrument configuration switch inCONFIG position.

2. Depress PAR button until displayshor ts :

3. Depress ‘raise’ or ‘lower’ button untillower display shows FAC:

4. Depress ‘raise’ or ‘lower’ button:


6. Acknowledge with the PAR button:

7. After about 5 seconds thecalibration procedure isc o m p l e t e d

DISPLAY:

Figure 7.2.1 Retrieving factory calibration


Calibration

Depending on the measurement range, different reference voltages must be calibrated in theinstrument. The necessary references are listed in Figure 7.2.2 and must be calibrated in thesequence given in the table.

REFERENCE1. 2 0 . 0 0 m V2. 5 0 , 0 0 0 m V3. CJC4. Pt100

MEASUREMENT RANGE INPUTMNEMONIC All thermocouples RTD Linear input

20.0 . # !

50.0 . . .CJC .r td .

# = required calibration

NOTE: Calibration must be performed in the order given in the table

Figure 7.2.2: Reference voltages

Remove the instrument from the panel and place it on a laboratory bench. Close the configura-tion link/switch and allow the instrument to warm up for at least 30 minutes. Connect theappropriate reference voltage: for calibrating the CJC the connection must be made with com-pensating cable (CJC of calibration source equivalent to type J thermocouple at all otherreferences are connected with copper wire (wires must be of identical length). See Figure .7.2.3 for the recalibration procedure using the 20mV reference as an example.


Cal ib ra t ion

B U T T O N O P E R A T I O N : DISPLAY:

1. Instrument switch in CONFIGpositionConnect calibration, source and setto appropriate value.

2. Depress PAR button until displayshows:

3. Depress ‘raise’ or ‘lower’ button untilappropriate reference appears:

4. Depress PAR button once::


6. Acknowledge with the PAR button:

7. After about 5 seconds the calibratorprocedure is completed.Select next reference to becalibrated and repeat procedure.

F igure 7.2.3 Reca l ib ra t ion

808/847 & 809/849 Installation and Operating Instructions 7 - 5

Calibration

linear input optionWith option QLS, linear input signals (mV and process signals with an appropriate inputadapter) can be connected to the input and conditioned according to a linear equation.

(example)

2. Set-up point(example)

10 20 30 40Input signal (mV)

Figure 7.3.1 Linear input

7-6 808/847 & 809/849 Installation and Operating instructions

Programmer/Controller

PROGRAMMER/CONTROLLER

Programmer/controller - FunctionModels 808 and 847 with option QLPS contain an in-built setpoint generator in addition to thecontroller function. This setpoint generator can produce a temperature/time profile with foursegments. When the program is running, the current setpoint from the setpoint generator is fedto the control algorithm. The current setpoint is continuously shown on the lower display.

To host computer

D i g i t a l C o m m u n i c a t i o n s

A ABase

setpoint

P r o g r a mgenerator

0C o n t r o l o u t p u t

c o n t r o l l e r

Feedback

M e a s u r e d v a l u e i n p u t

Figure 8.1.1 Conceptual block diagram of programmer/controller

The four segments are defined in the order: Ramp 1, Dwell period 1, Ramp 2, Dwell period2, and are executed in succession. The number of program repetitions (up to 200, or continu-ously [Cont]) can be set with the LC parameter; at the end of dwell period 2 the program goesback to the beginning. When the program is running, the parameter is decremented and thusshows the repetitions remaining.

A ramp consists of a slope (linear gradient) and a target setpoint. The control setpoint increas-es or decreases at a linear ramp rate from the actual measured value until a specified target set-point is reached. The relative positions of the actual measured value and the target setpointdetermine whether the slope of the ramp is positive or negative. Parameters rl and r2 express


Programer/Controller

the ramping rate in units per minute (0.01 to 99.99), parameters L1 and L2 the appropriate tar-get setpoint in display units (adjustable over the configured measurement range, but notrestricted by SP H and SP L). The starting setpoint for ramp 1 is always the current measuredvalue (servo). Even during a program repeat, the starting setpoint is always set equal to thecurrent measured value at the moment of reset.

In a dwell period, the target setpoint, which has been attained, remains unchanged for a fixedperiod. Both dwell periods are defined by their duration in minutes with parameters dl and d2(0 to 9999). When the program is running, these parameters display the time remaining in theactive dwell period. If the parameter equals zero, the dwell period is skipped.

Setpoint

Time TimeTime

Setpoint SetpointSetpoint value for 2nd iteration value for 2nd iteration end value of st iteration end value of st iteration

1st 1st Iteration 2nd Iteration2nd Iteration Time TimeTime

Figure 8.1.2 Program examples

Programmer/controller - StatesThe programmer/controller can be placed in three different states. Its state is determined bythe parameter Prog with the values IdlE, run and Hold. An additional, non-selectable state isholdback (Hb), described later.

If the programmer/controller has been placed in the IdlE state, it operates as a simple con-troller with the setpoint shown on the lower display. An entered program is not executed.

In the run state, the program has been started and is executing. When started from the IdlEstate, the program is always launched from the beginning, at the end of the program it returnsto IdlE. The current running segment is displayed together with the configured unit, bydepressing the PAR button once. A program which is running may be reset by selecting IdlE.

A program which is running (run) is halted by selecting Hold. The program generator stops


the program on the current setpoint. From the Hold state, the program can be continued (run)or reset (IdlE).

Setpoint Setooint

>I

Figure 8.2.1 Programmer/controller states

Programmer/controller - HoldbackThe holdback state (Hb) is a special case of Hold. It is activated of its own accord by the pro-grammer/controller and cannot be selected by the user. The Hb parameter allows the user toset the difference tolerated between the current setpoint and the actual value while the pro-gram is running. If this difference is exceeded, the program generator halts itself in order forthe process value to catch up with the program setpoint. Figure 8.3.1 shows the holdbackmode of operation. A ramp which is too steep for the system response is reduced to the maxi-mum possible rate for the process by the effect of holdback. In a dwell period the time-base ishalted. If the difference between setpoint and actual value is again smaller than Hb, the pro-gram is continued. The parameter can be altered within the limits of the measurement range.

To switch off holdback, set the parameter to a very high value.

Setpoint/actualvalue Holdback-

Process Value

match process

a n d

Ramp rate limited by process response: programmer alternating between HOLDBACKand RUN ensures matching of ramp rate



Setpoint/actualvalue

Process va lue

Time

Process value oscillates during dwell period: HOLDBACK stops the time basewhen process value outside holdback band

Figure 8.3.1 Holdback

Programmer/controller - Setpoint programmingThe state of the programmer can be modified in three ways. All three have the same priorityand the last action from any of them is acted upon:

. Via the digital communications board, by modifying the status word, see specialCommunications Handbook for Eurotherm Controls 800 series (Part no. HA020161).

. Via the front panel pushbuttons, by choosing the parameter Prog and selecting the parametervalue (IdlE, run or Hold). Rear terminals 16 & 17 must be bridged during this time, other-wise the instrument will immediately go into Hold when the program starts. If the program-mer/controller is placed from IdlE into Hold via the front panel pushbuttons, the program isboth started and then immediately halted.

Via the rear terminals 16 & 17 as shown in the description of the connecting terminals(Figure 2.3.8). If the instrument is configured as a programmer/controller, these terminals nolonger have the function of front panel lock-out, but assume the function of setpoint program-ming. Figure 8.4.1 shows the run sequence. Note that the programmer/controller goes into theIdlE condition only after the completion of a program, but cannot be placed there using therear terminals.



Programmer/controller - AnnunciatorsThe LED beacon R in the upper section of the display panel indicates the current state of theprogrammer/controller: . LED off IdlE. LED on * r u n. LED flashing Hold or Holdback

Programmer/controller - Parameter modificationModifications to the parameters specific to a particular program are differently interpretedaccording to the state of the programmer/controller.

In the IdlE state, all the parameters can be modified, the modification is permanent.

In the run state, the parameters specific to the program, LC, rl, L1, dl, r2, L2 and d2, cannotbe modified (including by digital communications). A modification is possible to the Hbparameter, the modification is permanent.

In the Hold state, the parameters specific to the program, LC, rl, L1, dl, r2, L2 and d2, canbe modified (including by digital communications), the modification is, however, not perma-nent and is valid only for the current iteration of the program. A modification is possible to theHb parameter, the modification is permanent.

c lose

o p e n

A. Program control through opening and closing of rear terminals

B. RUN/HOLD-Sequence while program is running

o p e n

close

C. Restarting program after completion of previous program

Figure 8.4.1 Use of rear terminals for program control



Ending a programAt the end of a program, the programmer/controller returns to the IdlE state and switches backto the normal control setpoint (SP). According to the target setpoint of ramp 2 and the normalcontrol setpoint, different conditions ensue. The setpoint can be modified as in normal closed-loop operation whilst the program is running and influences the end of the program. Figure8.5.1 shows a combination of all possibilities.

Setpoint setpoint

Times t a r t

Setpoint

e n d s t a r t

setpoint

end

d u r i n g program

s t a r t

Time

end

s t a r t end

Time

Figure 8.5.1 Methods of ending a program



Program recovery following loss of powerAll the instrument parameters are stored in non-volatile memory. When power is lost, the cur-rent point in the program is also stored in the memory. When power is restored, the program-mer/controller resumes the program in the appropriate segment at the point reached at themoment of interruption, as soon as the process value re-enters the holdback band.

Setpoint/actualv a l u e

Process value

Time

P o w e r f a i l u r e

A. Loss of power during ramp

Setpoint/actualv a l u e

POWER FAILURE

B . L o s s o f p o w e r d u r i n g d w e l l p e r i o d

Figure 8.6.1 Program recovery following loss of power


Self-tuning

SELF-TUNING

Self-tuning - General808 and 847 controllers have in-built self-tuning as a standard feature, which can be activatedby the user on demand. According to a special procedure, the instrument examines the processreaction curve and calculates by means of a complex computer algorithm the optimum controlparameters, using the data measured during the procedure. The parameters thereby obtainedafter successful tuning are automatically set into the instrument. Control parameters can beadapted in this way at any time for new or modified process reaction curves. It is not neces-sary to pre-adjust the control parameters before tuning, this is an important advantage overcustomary procedure.

Note: The adjustment procedures used here apply thermal shocks; in sensitive systems damagecan occur. The adjustment procedure relies on correct configuration of the controller for theprocess and can only work correctly if these pre-conditions are met.

If the instrument is used as a heat/cool controller with a non-linear cooling method (e.g. watercooling over 100 on output 2, the latter must be configured correctly (parameterOP 2 = H20), otherwise the cooling system can be damaged when self-tuning is activated.

Self-tuning works by two different procedures which are automatically selected:. Tune from ambient (measured value far from setpoint). Tune from setpoint.

A self-tune procedure from ambient is performed if, on activating self-tuning, the measuredvalue and the chosen tune setpoint are not near one another. This can apply to a normal heat-up or cool-down condition (when the cool channel is connected).

A self-tune procedure from setpoint is performed if, on activating self-tuning, the measuredvalue and the setpoint are approximately equal, e.g. when the process reactioncurve has con-verged. This procedure can be used for post-tuning the curve in the finalised control set-up.

Both types of self-tuning calculate the following control parameters:. Prop Proportional band 1nt.t Integral time constant. der.t Derivative time constant

In addition, the tune from ambient operation calculates the parameters:. H cb High cutback (start-up optimisation). L cb Low cutback (start-up optimisation)

Note: The adjustment procedure does not calculate the relative cool gain of a possible coolchannel. For correct parameter calculation using self-tuning, this ratio must be set in parame-ter rEL.C before activating self-tune. On tuning for a process which must be predominantlycooled (endothermic process) to achieve control, the procedure calculates the proportional


Self-tuning

band for the cool channel. Here, too, a correct setting of rEL.C is necessary before activatingself-tune.

Self-tuning - ActivationSelf-tuning can be activated under the following conditions: Operator level (not in configuration level). Automatic operating mode (closed loop). PID control algorithm (Pid, r SP, or Prog)

In the following circumstances, self-tuning is halted or overridden:

Tuning is halted when the controller is switched over from automatic to manual. It automati-cally begins afresh when switched back to closed-loop (if not switched off in between times).

In a power outage the process is interrupted. If automatic tuning is configured to take place onapplication of mains power, tuning re-starts when the power supply returns.

If the programmer/controller is executing a program, tuning cannot be activated during aramp. The program must be reset beforehand (IdlE) or halted (Hold).

If the instrument is configured as a PID controller with ramped setpoint (r SP), the tuningprocedure overrides the start-up ramp.

Self-tuning can be activated with two different parameters, the tuning setpoint can be adjustedfor about one minute after the start.

With the parameter tunE, the user can trigger an immediate tune. The parameter values onand OFF serve to activate and display the tuning procedure.

With the parameter t SU (start-up) a one-off tune is selected the next time power is applied tothe instrument. If the parameter is set to YES, no successful tune operation has taken place butone will automatically be launched the next time power is applied to the instrument. After asuccessful tune operation, this parameter reverts to no of its own accord.

Self-tuning - OperationThe diagrams on the following pages illustrate the self-tuning operation. In order to achievegood control results, the actual value should be broadly stable before the start. The algorithmfunctions even if the actual value is unstable but it evaluates this change as part of the processreaction curve.

During the course of the operation, the annunciation tunE flashes in the lower display. Duringthis period, do not change any of the instrument parameters. The tuning operation is finishedwhen the annunciation tunE no longer flashes in the lower display. The user can abort self-tuning at any time by setting the parameter tunE to OFF.


Sel f - tun ing

Tune from ambient:The desired setpoint for tuning can be adjusted with the raise or lower buttons for about oneminute. During this time the output level is reset to zero. Also at this time the influence ofadjacent zones on the specific zone is observed and compensated for in the algorithm. Afterthis the actual tuning operation begins, the instrument commands heat (if setpoint is greaterthan actual value) or cool (if setpoint is smaller than actual value) with maximum outputstrength. From the start-up process reaction curve, a fictitious setpoint is determined (CP),which lies somewhat below (above) the setpoint to be tuned in order to exclude overshoot(undershoot). On reaching this value, the output is switched off and oscillations are forcedthrough repeated switching (see diagram).

The control parameters are then calculated from the recorded data of the reaction curve (delaytime, heating rate, period and amplitude of the forced oscillation,...) and are storedindependently in the instrument. The tuning operation is successfully completed.

Note: If the cool channel output is configured for non-linear cooling (e.g. water cooling over100 H20) the maximum output level during cooling is only 20% in order to avoidexcessive thermal shocks through non-linearity.

Process value

Tune from ambient - heat u p

Figure 9.3.1 a Tune from ambient

808/847 & 809/849 Installation and Operating instructions 9-3

Self-tuning

Process value

Process reaction curve

output

Tune from ambient - cool down

Figure 9.3.1 b Tune from ambient


Sel f - tun ina

Tune from setpoint:After initiating a self-tune from setpoint, the output power is fixed for one minute at theoriginal value. If during this time a new setpoint is set, the instrument automatically switchesto tuning from ambient. Again at this time, the influence of adjacent zones on the specificzone is observed and compensated for in the algorithm. After this, both outputs are switchedoff for a short while and the process reaction curve is observed. In either the case of anexothermic process (heat removal) or an endothermic process (independent heat supply),oscillations are induced at the fictitious setpoint (CP) by switching on the heat or cool channel.

Here too,,the control parameters are calculated from the data acquired from the reaction curveand are stored independently in the instrument. The high and low cutback levels are not calcu-lated, but are checked to ensure that they do not lie within the proportional band. Should thisbe the case, they are moved out to the edge of the proportional band and therefore becomeinactive. The tuning operation is successfully completed.

Process value

PV4

Tune from Setpoint - endothermic process

Figure 9.3.2a Tune from setpoint


Self-tuning

Process value

CP I....................,

fictitious Setp

output

1 0 0 %

0 %

-Setpoint-

PV4

Tune from Setpoint - endothermic process

Figure 9.3.2b Tune from setpoint


Self-tuning

Self-tuning - Abort conditionsIn some cases, the self-tune routine aborts spontaneously due to external influences in the pro-cess being tuned for by the instrument.

In a heat-only controller, this is the case when, for example, through the influence of an adja-cent zone, the process is heated up to the setpoint without its own heat source. The tuningalgorithm recognises such a case and aborts the tune of its own accord after a time (dependingon the process reaction). Although the parameters are calculated from the data acquired up tothat point, an incorrect adjustment is possible.

The same case applies for a heat/cool controller; here too parameters are still calculated,although a complete tune has not been performed.

Process value

Tune from ambient - heat only, abort

Figure 9.4.1 a Self-tuning, abort


Self-tuning

Process value

C l

fictii

- S e t p o i n t

Tune from ambient heat/cool, abort

Figure 9.4.1 b Self-tuning, abort


Register

INSTRUMENT REGISTEROn the following pages is an instrument register for models 808 and 847 digital controllers.Record data here for each individual instrument. In the parameter tables, up to three differentparameter adjustments can be recorded.

Instrument Serial No. Year Month Softwareversion

Basic Output modules Input SpecialInstrument output 1 output 2 output 3 Comms Adapter Functions

Linearisation Measurement Display Output configuration

Type Range Units output 1 output 2 output 3

u u u u u u

Calibration code for linear input:Input Signal Measurement range

Min. Max. Units Min. Max. Units

808/847 & 809/849 installation and Operating Instructions 10-l

Register

Mnemonic Parameter

LOWER PARAMETER LEVEL

none Output level(Manual only)

C or F Display units(Display only)

OUTPUT POWER LIMITSH PL Max. power output

Sensor break power output I

Measured value inputCalibration offset

C F unit selectionSn Sensor linearisation select

DIGITAL COMMUNICATIONSAddr Instrument address

Baud rate I I

AlarmsHi Al Full-scale high alarmLo Al Full-scale low alarmd Al Deviation alarm

CONTROL PARAMETERS bandI time constanl

t I Deriotive time constant I I I

H c.tc c.tH cb

L cb

Relative gainHeat cycle timeCool cycle timeHigh cutback start-upoptimisationLow cutbackstart-up optimisation

Installation and Operating Instructions

Register

Mnemonic Parameter

CONTROL PARAMETERS

SETPOINT LIMITSSPH Setpoint high limitSPL Setpoint low limit

ALARM 1 OUTPUTHA0 Full-scale high alarmL A O Full-scale low alarmdA0 Deviation band alarm

INSTRUMENT CONFIGURATIONidno Identification numberCtrl Control algorithmSPrr Setpoint ramp rateOPl output 1

(Hardware configuration)OP2 output 2

(Hardware configuration)AH Automatic/manual enableCJC Cold junction compensationPb dPH-L

t su**

Proportional band displayProportional band scalefactorTune on start-up

Cb Cutback operation

LINEAR INPUT (Option QL...)Act Control senseHi L Measurement range upper

limit (sensor break)Lo L Measurement range lower

limit (sensor break)Fil Input filter

From software version 02.00 **From software version 03.00

808/847 & 809/849 Installation and Operating Instructions 1 o-3

Supplements

SUPPLEMENTS RELATING TO 809/849 VALVE POSITIONERCONTROLLERSThe dimensions, technical data, operation etc. are equivalent to the 808/847 controller seriesand can be taken from the appropriate chapters of this manual.

Further information is contained in the 809/849 series.

Valve positioner controller output (motor open/close)

Relay output (VPR) or triac output (VPT)

More (open) Terminals 1& 2

Less (close) Terminals 3 & 4

logic or d c Triac or R e l a y- r RS-422

3 13

O v e r r i d e o f c o m m u n i c a t i o n si n i t i a t e d f r o n t - p a n e l d i s a b l e

RS-232-c

C o m m o n

TDX

R D X

Figure 10.1 Terminal allocation for valve positioner controller


Supplements

Additional parameters for valve positioner controllerYou will find general parameters for the 809 in Chapter 6.3, parameter list.

In addition, the following control parameters (see Figure 6.3.2) may be accessed andmodified:

Display mnemonic Parameter Adjustable range Functiontt TT Motor travel time 0.1 to 240s Motor travel timec t TM Cycle time 0.1 to 240s Output cycle frequency

(periods for ON and OFF)inrt TN Motor inertia time 0.000 to 1 .Os Inertia (motor inertia time)blSh BK Motor delay time 0.0 to 20% of Mechanical backlash

(mechanical motion rangebacklash)

Adjustment note: Motor travel time, - use the value from the manufacturers’ data sheet or mea-sure the travel time using manual mode. The cycle time must be very much shorter than themotor travel time (<5%).

The following configuration parameters (see Section 6-7) are differentDisplay Parameter Adjustable range CommentsCtrl Control algorithm On/off On.Of

Valve positioner v A L vValve positioner withramp to SP rSPValve positioner withSP programming Prog Available only if

option QLPS installed

The parameters for outputs 1 & 2 in Section 6-7 are not applicable as they are not used in thevalve positioner controller.

Self-tuning for valve positioner controllerModels 809/849 valve positioner controllers incorporate self-tuning as a standard feature. Thefundamental function of self-tuning, as well as its operation and launching, are essentiallyidentical to that of the 808/847. You will find an explanation of this in Chapter 9 of this manu-al.

Please note the following difference: as the valve positioner controller operates with a PI algo-rithm, only the proportional band (ProP), integral time constant (1nt.t) and if necessary, cut-back parameters are calculated, the derivative time constant is not applicable. To launch tun-ing, control algorithm type PI must also be configured (vALv, r SP or Prog).


MODEL 808/847 UNIVERSAL PID … 808/847 UNIVERSAL PID PROGRAMMER/CONTROLLER MODEL 809/849...

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